VSB VALLOUREC & SUMITOMO TUBOS DO BRASIL LTDABLAST FURNACES 1 & 2PLANT OF JECEABADATA BOOKSINGLE STAGECENTRIFUGAL BLOWERSTURBLEX INC.AReviso 21/08/2009 RDA RDA RDA0Emisso Inicial 20/07/2009 RDA RDA RDARev. No.Rev. No.Descrio da RevisoDescription of RevisionDataDatePreparadoPreparedChecadoCheckedAprovadoApprovedTtulo do Documento:Title of Document / Designation:Nmero PW:PW Number:Rev.1375-02-0065ADocumentos de Referncia:Reference Documents:DATA BOOKSINGLE STAGECENTRIFUGAL BLOWERSTURBLEX INC.C-81/1375/OC/005Nmero VSB:VSB Number:Rev. Nmero Subfornecedor:Subsupplier Number:Rev.Nmero total de pginasNumber of pages PRELIMINARY OPERATION & MAINTENANCE MANUAL FOR VALLOUREC & SUMITOMO TUBOS DO BRASIL LTDA BRAZIL SINGLE-STAGE CENTRIFUGAL BLOWERS July 30, 2009 VOLUME 1 OF 1 CONTAINS ITEMS A K TURBLEX JOB #08104607T 1635 W. WALNUT SPRINGFIELD, MO65806 PHONE:417-864-5599 FAX:417-866-0235 www.turblex.com 1635 W. Walnut Street Springfield, Missouri65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail:turblex@turblex.com Web Site:www.turblex.com OPERATION & MAINTENANCE MANUAL TABLE OF CONTENTS ItemDescription -Title/Cover Page -Table of Contents AGeneral Information a.Safety Precautions b.Receiving & Handling c.Recommended Lifting Diagram - 4 Point Lift d.Storage Requirements e.Vibration Isolator Installation Instructions f.Instrument Installation Instructions g.Allowable Load on Compressor Discharge Flange h.Recommended Lubricants for Turblex/HV-Turbo Compressors i.Suggested Preventative Maintenance Schedule j.Sample Blower Data Log Sheet k.Turblex/HV-Turbo Service & Spare Parts Capabilities l.Service/Engineering Rate Schedule m.Turblex Recommended Spare Parts n.Troubleshooting Guide B Compressor Information a. Compressor Nameplate Data b. Description of Turblex/HV-Turbo Compressor c. VD Description of Operationd. Surging & Recirculation e. Performance Datasheet (PDS) f . Speed Torque Curve C Operation Description a.Local Control Panel Operation Description b.Local Control Panel Operator Interface/ Screens c.Operating Restrictions d.Instrument Setpoints D Drawings a.General Arrangement Drawing(s) and Installation Notes b.Process & Instrumentation Diagram(s) c.Local Control Panel Electrical Diagrams E Coating System FPerformance/Functional/On-Site Testing a.Compressor Performance Test Report b.Motor Test Report c.Functional/On-Site Testing GPre-Startup Inspection Checklist H Turblex Equipment Warranty IList of Components J Appendix a.Center of Gravity Calculations b.Vibration Isolator Natural Frequency and Transmissibility c.Instrument List K Quality Manual L:\Project_Engineering\Jobs\4607T\Engineering\Mechanical_Eng\O&M\Electronic_O&M\4607T Tblecnts Prelim O&M.doc.aj1635 W. Walnut Street Springfield, Missouri65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail:turblex@turblex.com Web Site:www.turblex.com ITEM A SAFETY PRECAUTIONS 1.ROTATING EQUIPMENT HAZARDS:Beware of the rotating equipment hazards around the blower and motor area.Avoid wearing loose clothing and stay at least three (3) feet away from unit during normal operation. 2.AUTOMATIC EQUIPMENT HAZARDS:Beware that the equipment can start AUTOMATICALLY.All site tag-out/safety lockout procedures must be followed when working or standing on this equipment.The coupling guard, which is painted safety yellow, must be in place at all times.Site tag-out/safety lockout procedures must be followed if the coupling guard is removed for any reason. 3.NOISE HAZARDS:This equipment operates at noise levels of 80 dB(A) and above.All entrances to the blower building must be posted with the appropriate OSHA warning signs.OSHA-approved ear protection must be worn when working in the blower building while the equipment is in operation. 4.ELECTRICAL EQUIPMENT HAZARDS:Beware of the low and high voltage power requirements of the control panels and the motors.All site tag-out/safety lockout procedures must be followed when working inandaroundthisequipment.TheappropriateOSHAsafetywarningsshouldbepostedwhere necessary. 5.PRESSURIZED OIL HAZARDS:The lube oil system may consist of a pumping system, which supplies oiltotheblowerbearingsatpressuresupto120psi.Usethepropersitetag-out/safetylockout procedures before performing maintenance operations. 6.MOVING AIR HAZARDS:Remove all loose objects and equipment from the vicinity of the blow-off outlet. Usethepropersitetag-out/safetylockoutproceduresbeforeremovinganypipingfromtheinletor discharge of the compressor, including the changing of inlet air filters. 7.SAFETY EQUIPMENT:All site safety equipment rules and procedures must be followed when in this area.This includes wearing proper protective goggles, ear muffs, shoes, clothing, etc. 8.EMERGENCY SHUTDOWN OF THE EQUIPMENT:Should an emergency occur, the equipment will automatically shutdown or can be physically shutdown by pushing the red emergency stop (E-Stop) button located on the front of the appropriate local control panel (LCP) door.CAUTION:Surging will occur when the equipment is shutdown in emergency-stop situations.This is considered normal and will not damage the equipment. 9.SPECIAL HV-TURBO BLOWER TOOLS:This equipment is provided with a special set of tools, which are required to perform certain maintenance and repair operations.These tools are provided in a specially marked toolbox, and should be maintained for their respective uses only.Failure to use the appropriate tools for maintenance and repair operations may damage the equipment and/or injure service personnel. Z:\Submittal_O&M\Master_Sub\Item_A_GenInfo\Source_Docs\Safety_Precautions.doc Document Name: 4607T-Item A Rev A1635 W. Walnut Street Springfield, Missouri65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail:turblex@turblex.com Web Site:www.turblex.com Z:\Submittal_O&M\Master_Sub\Item_A_GenInfo\Source_Docs\Receiving_&_Handling.doc ITEM A RECEIVING & HANDLING Care is taken at the factory to ensure the compressor arrives at its destination in first class condition.Inspect unit to make sure no damage has occurred during shipment.Make the examination before removing from the truck.If damage or indication of rough handling is evident, file a claim with the carrier at once, and notify Turblex. Eachcompressorskidassemblyisprovidedwithliftinglugsatthefourcornersofthe base/skidforliftingtheassembledmachine.Theequipmentneededtohandlethe compressorskidassemblyshouldincludeahoistandspreaderbararrangementof sufficient strength to lift the compressor assembly safely.The spreader bar should have lifting hooks positioned to equal the span of the lifting lugs.An experienced rigger should be used to handle the equipment. CAUTION Uneven lifting must always be avoided.Slings of equal lengths must always be used to avoid uneven lifting, when single point lifting is to be used. CAUTION Lifting lugs or eyebolts on the motor/compressor are designed for handling that equipment only.They are not to be used to lift the compressor assembly. WARNING Failure to observe these precautions may result in damage to the equipment or injury to personnel. I T E M A1635 W. Walnut Street Springfield, Missouri65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail:turblex@turblex.com Web Site:www.turblex.com STORAGE REQUIREMENTS If the compressor is not to be installed and placed into service immediately, certain normal precautions must be taken after it has been received to provide proper protection while the compressor is being stored. A unit is considered to be in storage when: 1.It has been delivered to the jobsite and is awaiting installation 2.It has been installed, but operation is delayed pending completion of plant construction 3.There are long periods between operating cycles 4.The plant is shut-down Storage requirements for up to six (6) months prior to start-up: The compressor and all accessories, including any free standing control panel, valves, silencers, enclosure, instruments, and spare parts must be stored indoors, under cover, in a clean, dry location.Since moisture can be very detrimental to electrical and rotating equipment, the ambient temperature must be maintained above 50F (10C), with relative humidity less than 90%, by providing either external or internal heating.If the motor is equipped with space heaters, they must be energized at the voltage shown by the space heater nameplate attached to the motor.Incandescent light bulbs can be placed within the motor or control panel to provide heat.However, if used, they must not be allowed to come in contact with any parts of the motor or control panel because of the concentrated hot spot that could result.Avoid exposing compressor and sensitive components to vibration. Additional storage requirements after first six (6) months prior to start-up: Compressorsandmotorshavingsleevejournalbearingsareshippedwithoutoilinthereservoirs.Instorage,the reservoirsmustbeproperlyfilledwiththemanufacturersrecommendedlubricant.Greaselubricatedmotorsare generally shipped with the bearings lubricated and ready for operation. To prevent the bearings from flattening and the shaft journals from pitting, rotate the compressor and motor shafts one-half turn (180) every two (2) to three (3) weeks.If the unit is supplied with an electric oil pump, run electric oil pump for 30 minutes to thoroughly lubricate the bearings prior to rotating the shafts. To prevent the control vanes from sticking, cycle the vanes open and close at least two (2) cycles every two (2) to three (3) weeks. Provide temporary power to the local control panel in order to run the electric oil pump, if supplied, and cycle the control vanes.If the control panel is not pre-wired to the compressor skid assembly, provide temporary connections between motor starters located in the control panel and the terminals in the junction box at the skid assembly.If the control panel is provided with umbilical cords for quick and easy connections to the skid assembly, plug the umbilical cords into the connectors at the skid assembly. Recommended storage procedures after start-up: If the compressor is to remain idle for more than 60 days, follow the above pre-start-up storage requirements. In addition, place the compressor control in the service mode and cycle the valves open and close at least two (2) cycles every two (2) to three (3) weeks.The local control panel is to remain energized while the compressor is idle. NOTE: For more details on motor storage requirements, refer to motor manufacturers instructions in the Operation and Maintenance Manual. WARNING Warranty will be voided if storage instructions are not followed. Z:\Submittal_O&M\Master_Sub\Item_A_GenInfo\Source_Docs\Storage_Reqmts.doc ITEM A 1635 W. Walnut Street Springfield, Missouri65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail:turblex@turblex.com Web Site:www.turblex.com ITEM A VIBRATION ISOLATOR INSTALLATION INSTRUCTIONS FOR XLW TYPE FOR USE WITH MODELS KA22 KA66 COMPRESSORS Proper baseplate leveling is critical and must be achieved in strict accordance with the following instructions prior to start-up. Transverselevelistobesetoverthewidthofthebaseplatebyplacinga machinist level on skid beams. Longitudinal level is to be set over the length of the baseplate by placing a machinist level on the motor shaft. Thevibrationisolatorsaresuppliedassembledwitha6x12xthickmounting plate and related fasteners. INSTALLATION STEPS 1.Lowerthecompressorintopositionontheconcretefloorwhilepositioningthe isolators using the holes in the skid and fasteners provided.The top plates of the isolators should rest on their respective housings prior to adjustment.Check for isolators where the top plates do not touch the housings and measure the distances. Thisindicatesthattheseisolatorsarerestingonlowspotsonthefloor.Ifthe isolator top plates are resting on the housings, and a level bubble confirms that the baseplate is not level, then the isolators are resting on the high spots on the floor.Check the skid to be sure that it is resting level. 2.If the distance between the top plates and the housing is more than 1/16, shims may be inserted between the top plates and the compressor base to shorten these distances to within 1/16.If shims are used, they must be at least the same size as the top plate of the isolators.If the distance is greater than , this indicates that the concrete in these areas is excessively low (below ) and must be filled in with epoxy and allowed to harden.Alternatively, the high spots under the isolatorswhere the top plate is resting on the housingcan be ground down to narrow the gap between the top plate and the housings of the isolators located in the low spots. 3.Once all isolator top plates are either resting on the housings or within 1/16 of the housing, and the compressor base is level, scribe a mark around the 3/4' isolator mounting plates. 4.Remove the skid to isolator attachment fasteners, lift the compressor away from the area, and remove the isolators from their mounting position. ITEM A VIBRATION ISOLATOR INSTALLATION INSTRUCTIONS FOR XLW TYPE FOR USE WITH MODELS KA22 KA66 COMPRESSORS 2 5.The area is now ready for the vibration isolators to be glued to the floor.Follow the directions on the Loctite Depend Adhesive package supplied and apply the adhesive tothescribedareaonthefloor.Useenoughadhesivetocompletelycoverthe isolator scribed area.Apply the activator to both the concrete and the bottom of the isolator mounting plates. 6.Within 15 minutes after the activator is applied, set the isolators into place on the scribed areas taking care to be sure the mounting plates register properly with the glue.Set the skid on top of the isolators taking care to align the isolator and skid mountingholesandattachtheskidtotheisolatorswiththefastenersprovided.Allow a drying time of 4 hours minimum for the adhesive to reach approximate full strength before leveling the compressor. 7.Adjust the isolators so that the top plates are a minimum of or a maximum of off the housings.Start at one isolator by turning its adjusting nut clockwise four (4) times,thenmovetothenextisolatorandturnitsadjustingnutfour(4)times.Continue this procedure until the top plates of each of the isolators are to off their respective housings.Check the skid to be sure it is level.The skid may now be leveled by making small adjustments of individual isolators at the high and low points. 8.After the equipment is level, visually check each isolator to make sure spring coils arenotclosedsolidandthereissufficientclearancebetweenthetopplateand housing. Z:\Submittal_O&M\Master_Sub\Item_A_GenInfo\Source_Docs\Vibo_Install_XLW_Type.doc INSTALLATION STEPS FOR XLW VIBRATION ISOLATORXLWVIBRATIONISOLATORSTEP1aISOLATOR1/2-13BOLT1/2- LOCKWASHER1/2- WASHERXLWVIBRATIONISOLATORSTEP 1bNOGAP1. NORMALIFSKIDISLEVEL2. INDICATESISOLATORISRESTINGONAHIGHSPOTIFSKIDISNOTLEVELXLWVIBRATIONISOLATORSTEP1cGAPMEASURE1. INDICATESISOLATORISRESTINGONALOWSPOTXLWVIBRATIONISOLATORSTEP2aISOLATORSHIM1. IFGAPISMORETHAN1/16INCHBUTLESSTHAN1/4INCHADDSHIMSXLWVIBRATIONISOLATORSTEP2bGAP1. IFGAPISMORETHAN1/4INCHFILLAREAWITHEPOXYTOLEVELXLWVIBRATIONISOLATORSTEP2cNOGAP1. HIGHSPOTSCANBEREMOVEDTOCLOSETHEGAPOFISOLATORSLOCATEDINLOWSPOTSx x x x x x xXLWVIBRATIONISOLATORSTEP2dGAP1. GAPONALLISOLATORSSHOULDBEFROM0-1/16INCHXLWVIBRATIONISOLATORSTEP3XLWVIBRATIONISOLATORSTEP4aREMOVEFASTENERSITEMAINSTALLATION STEPS FOR XLW VIBRATION ISOLATORXLWVIBRATIONISOLATORSTEP4bXLWVIBRATIONISOLATORSTEP4cXLWVIBRATIONISOLATORSTEP5aXLWVIBRATIONISOLATORSTEP 5bXLWVIBRATIONISOLATORSTEP 5cXLWVIBRATIONISOLATORSTEP5dXLWVIBRATIONISOLATORSTEP6a1263 91263 9XLWVIBRATIONISOLATORSTEP6b63 93 912126XLWVIBRATIONISOLATORSTEP7aCHECKGAPTURNADJUSTINGNUTCW4TURNSPERISOLATORANDREPEATUNTIL1/4TO1/2INCHGAPISACHIEVEDADJUSTINGNUTITEMAINSTALLATION STEPS FOR XLW VIBRATION ISOLATORXLWVIBRATIONISOLATORSTEP7bADJUSTINGNUTCWRAISESSKIDCCWLOWERSSKID1. CHECKTRAVERSEANDLONGITUDINALLEVELOFSKID2. ADJUSTLEVELASREQUIREDXLWVIBRATIONISOLATORSTEP8SPRINGCOILTOCOILCLEARANCE1. SPRINGCOILSSHOULDNOTCONTACTEACHOTHER2. ADJUSTGAPASREQUIREDTOOPENCOILCLEARANCEITEMA1635 W. Walnut Street Springfield, Missouri65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail:turblex@turblex.com Web Site:www.turblex.com INSTALLATION INSTRUCTIONS FOR FIELD MOUNTEDINSTRUMENTS 1. Install Tubing between High-Side of Differential Pressure Transmitterandpitottubeatdischargecone. Recommended tube size is 5/16 stainless steel. PITOTTubewithprocessconnections, oneoneachside.Installtubingfrom differentialpressuretransmitterhere.If supplied, install discharge pressure gauge on opposite side. DifferentialPressure Transmitterwith process connections. Processconnections.Oneoneach side.Ifsupplied,installdischarge temperature gauge or transmitter here or on opposite side.Reinstalloiltemperature gaugewhenshipped loose.Reinstalloilpressure gaugewhenshipped loose.ITEM A 1635 W. Walnut Street Springfield, Missouri65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail:turblex@turblex.com Web Site:www.turblex.com INSTALLATION INSTRUCTIONS FOR FIELD MOUNTEDINSTRUMENTS 2. Installtubingbetweenlow-side ofDifferentialPressure TransmitterandInlet Filter/Silencershroud. Recommendedtubesizeis 5/16stainless steel. ITEM A InletFilterDifferentialPressure Gauge/Switch.Ifsupplied,install conduitsandwirestoLocalControl Panel (LCP). Inlet Filter/Silencer Differential Pressure Transmitter InletFilter/Silencershroudwith processconnection.Install tubing from differential pressure transmitter here. 1635 W. Walnut Street Springfield, Missouri65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail:turblex@turblex.com Web Site:www.turblex.com INSTALLATION INSTRUCTIONS FOR FIELD MOUNTED DEVICES Discharge Valve Blow-Off Silencer Discharge Cone Discharge Check Valve See Note 1A pipe spool piece (minimum one pipe diameter) must be installed between the check valve and the discharge valve to allow clearance for the valve plates to open Note 1:Pleasenote,regardlessofthedischargeorientationoftheblower,Turblex recommendsthedischargecheckvalvebeinstalledinthehorizontalposition.The discharge check valve is to be installed as close to the discharge cone as possible.If it is not installed in the horizontal position, please notify Turblex.The hinge post must be in the vertical position. Vibration Isolators Local Control Panel Blow-Off Valve Discharge Expansion Joint ITEM A 1635 W. Walnut Street Springfield, Missouri65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail:turblex@turblex.com Web Site:www.turblex.com Z:\Submittal_O&M\Master_Sub\Item_A_GenInfo\Source_Docs\Allowable_Load_on_Comp_Dischrg_Flange_Eng.doc ITEM A ALLOWABLE LOAD ON THE COMPRESSOR DISCHARGE FLANGE The discharge air dynamic forces are absorbed by the static restraint of the base assembly.Likewise, the dynamicforcesinthedischargepipingmustberestrainedbyindependentmountingandsupportofthe discharge piping. The allowable misalignment forces, which can be applied to the compressor discharge flange through the deflection of the expansion joint, are listed in the table below. See Figure 1. Fax=Forces in the discharge pipe direction.Flat=Forces perpendicular to Fax. M=Moment in any direction. TYPE FAX LB. FLAT LB. M IN. LB. KA2 KA5 KA10 KA22 KA44 KA66 KA80 KA100 247 607 899 1236 1708 2248 3035 3934 74 180 270 360 495 675 900 1124 575 1991 3098 5310 7965 13275 17700 30976 FlatFaxM1635 W. Walnut Street Springfield, Missouri65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail:turblex@turblex.com Web Site:www.turblex.com L:\Project_Engineering\Submittal_O&M\Master_Submittal\Item_A_GenInfo\Source_Docs\Recomm_Lubricants_GA_GB_GC_GL_Gearbox.doc ITEM A RECOMMENDED LUBRICANTSFOR TURBLEX/HV-TURBO COMPRESSORS WITH JOURNAL BEARINGS FOR USE WITH GA, GB, GC, & GL SERIES GEARBOXES EXCEPT KA100-GL500 COMPRESSOR COMPANY TRADE NAME VISCOSITY GRADE cSt @ 40C cSt @ 100C BPBP Bartran HV 464646.508.22 CastrolDual Range HV4646.507.90 ChevronRando HDZ ISO 464646.008.60 CITGOA/W Hydraulic Oil 464646.506.80 76 Lubricants by Conoco Philips76 UnaxAW 464646.57.00 DrydenParadene 46AW4645.896.72 ExxonNuto H 464646.006.70 MobilDTE 254644.206.65 Petro-CanadaHydrex AW464645.706.70 PrimroseSyn-0-Gen 464658.5010.10 Royal PurpleSyndraulic 464646.007.10 Schaeffers Mfg112 HTC ISO 464648.507.10 ShellTellus Premium 464646.006.80 Valvoline Premium Anti-wear Hydraulic Oil 4646.206.70 Lubrication Engineers Int. LE 6110 Monolec Hydraulic Oil 4648.806.84 LubriplateLubriplate HO-464642.007.00 Ultramar Canada Inc Hydraulik AW 464645.706.70 Oil Temperature Limits In Oil Reservoir: Normal: 120F-130F/50C-55C Maximum: 160F/71.1C Minimum: 50F/10C NOTE:If the above recommended lubricant is not available, please provide alternate oil specification data sheet and MSDS to Turblex for approval.If improper lubricant is used, any damage that could be caused by this will not be covered under Turblex warranty. OIL VOLUME PER BLOWER____________GALLONS. 275(1041Liters)1635 W. Walnut Street Springfield, Missouri65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail:turblex@turblex.com Web Site:www.turblex.com ITEM A SUGGESTED PREVENTATIVE MAINTENANCE SCHEDULE ROUTINE INSPECTIONS (by Plant Personnel) Inspect for cleanliness and general condition of compressor assembly unit Inspect and replace inlet filter(s) as required Inspect and clean/change oil filter(s) as required (if applicable) Check lube oil level and sample/change oil as required Test safety switches Verify all 4-20 mA current loops are operating properly Verify surge detection unit operates properly (See Item I 1370) ANNUAL INSPECTIONS (by Plant Personnel) Repeat routine inspections, plus - - - Inspect inlet silencer for cleanliness and general condition Verify discharge check valve operates properly to prevent back flows Inspect control arm(s) of variable control vanes for slippage Inspect and tighten all mechanical and electrical connections Check coupling alignment and tightening torques of all bolts 18,000 HOURS -CLASS I INSPECTION (air-end only) First inspection, after 18,000 hours of service (or sooner if site conditions dictate); thereafter, based on conditionsandappearanceofoperatingmechanisms.Estimatedservicetime:2-4days,perunit, assuming one (1) local helper and crane facilities.A Class I Inspection includes the following: Repeat routine and annual inspection, plus - - - Dismantle compressor air-end Inspect and clean variable vane system Check variable vane geometry Check axial movement on high and low-speed shafts Dismantle gearbox (GK series gearbox only) Replace fast shaft ball bearings (GK series gearbox only) Check unit alignment before re-start as required 36,000 HOURS -CLASS II INSPECTION (air-end and gearbox) Only GC and GK series gearboxes require Class II inspections after approximately 36,000 hours of service.Other gearboxes may require Class II inspections only based on conditions and appearance of operating mechanism during Class I inspection. Estimated service time:2-7 days, per unit, assuming one (1) local helper and crane facilities.A Class II Inspection includes the following: Repeat Class I Inspection, plus - - - Dismantle gearbox Inspect gearwheels, bearings & seals and check clearancesReplace roller/ball bearings (GC series gearbox only) Replace slow shaft ball bearings (GK series gearbox only) Replace flexible seals (O-rings) Inspect electric motor, oil pump, oil cooler, coupling, valves, etc. 2 Z:\Submittal_O&M\Master_Sub\Item_A_GenInfo\Source_Docs\Sugg_Prev_Maint_Sch.doc DRIVE MOTOR (by Plant Personnel) Keep motor clean and ventilation openings clear of dust, dirt, or other debris.Lubricate bearings every 3 months.Follow instructions found in the Components section of this manual (Item I). DRIVE COUPLING (by Plant Personnel) N10 Coupling (used on all compressor models except KA2-GK2/B3): Check alignment and outer blades of disc-packforfatiguecracksevery12months.Checktighteningtorquesofalldrivebolts.Follow instructions found in the Components section of this manual (Item I). T10 Coupling (used on KA2-GK2/B3): Inspect seal ring and gasket every 12 months.Re-lube coupling basedonrecommendationoflubricantmanufacturer.Checktighteningtorquesofalldriveboltsand fasteners.Follow instructions found in the Components section of this manual (Item I). AUXILIARY OIL PUMP MOTOR (If applicable, by Plant Personnel) Keep motor clean and ventilation openings clear of dust, dirt, or other debris.Lubricate bearings every 3 years.Follow instructions found in the Components section of this manual (Item I). MAIN OIL PUMP MOTOR (If applicable, by Plant Personnel) Keep motor clean and ventilation openings clear of dust, dirt, or other debris.Lubricate bearings every year.Follow instructions found in the Components section of this manual (Item I). LUBE OIL FILTER (If applicable, by Plant Personnel) Check filter indicator frequently to determine when the element needs servicing.Follow instructions found in the Components section of this manual (Item I). CHANGE OF LUBE OIL (by Plant Personnel) Thelubeoilshouldbechangedafterthefirst500hoursofoperation.ForGA,GB,GCandGLseries gearboxes, subsequent oil samples should be evaluated by an oil analysis service every three (3) months, with change of lube oil to take place according to the recommendation of the oil analysis service.ForGKseriesgearbox,subsequentoilchangeistotakeplaceevery6,000hoursof operation. SOLENOID VALVE AND BUTTERFLY VALVE (If applicable, by Plant Personnel) While unit is off-line, operate the valve once a month to insure proper opening and closing. To schedule a Turblex Field Service Technician for assistance, please contact the Turblex Service Department (Tel:417-864-5599; Fax:417-866-0235) approximately two weeks prior to shut-down.Rates would be per the most current published Turblex Service Rate Schedule.Estimates are available upon request. BLOWER DATA LOG SHEET - COMPRESSOR DATE:0800 1200 1600 2000 2400 0400HOUR METERVARIABLE DIFFUSER POSITION (SCALE)INLET GUIDE VANE POSITION (SCALE)INLET TEMPERATUREDISCHARGE TEMPERATUREOIL PRESSUREOIL TEMPERATURENOTE:This chart or facsimile should be filled out on each shift.U:\Sub-O&M\Blower Data Log Sht.xlsITEM A1(SAMPLE)TIMEINSTRUMENTS1635 W. Walnut Street Springfield, Missouri65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail:turblex@turblex.com Web Site:www.turblex.com Z:\Submittal_O&M\Master_Sub\Item_A_GenInfo\Source_Docs\Svc_Spare_Parts_Capabilities.doc ITEM A TURBLEX/HV-TURBO SERVICE & SPARE PARTS CAPABILITIES Turblex in Springfield, Missouri, has field service engineers/technicians capable of reacting within 24 hours to emergency service needs. Spare and replacement parts commonly used for bearing replacement, O-rings, and gaskets, are maintained as stock components, and are available for overnight shipment from Springfield, Missouri. HV-TurboinHelsingor,Denmark,maintainsastaffofserviceengineersandtechnicianson24-hour emergency notice from the Helsingor plant. Acompletestockofstandardrepairandreplacementparts,forallmachinesizes,aremaintainedin Springfield, Missouri. 1635 W. Walnut Street Springfield, Missouri65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail:turblex@turblex.com Web Site:www.turblex.com ITEM A 2009 INSTALLATION & COMMISSIONING ENGINEERING RATE SCHEDULE USD DESCRIPTIONHOUR/DAY/MILE Factory Representatives normal working hours (Monday through Friday)$150.00/hr 1st through 4th working hours in excess of normalworking hours and working on Saturday225.00/hr Additional overtime hours and working on Sunday and national holidays$300.00/hr Engineering Personnel normal working hours (Monday through Friday)$200.00/hr 1st through 4th working hours in excess of normal working hours and working on Saturday$300.00/hr Additional overtime hours and working on Sundayand national holidays$400.00/hr Traveling hours$150.00/hr Helper working/traveling hours$75.00/hr AirfareCost, plus 15% Per diem (domestic), including:lodging, car rental, telephone, fax, meals, gas$290.00/day International per diem, including: lodging, car rental, telephone, fax, meals, gas, Cost, plus 15% Helper per diem (less car rental)$205.00/day Traveling expenses by Company car/truck per mile$0.65/mi Charge for waiting time on Saturdays, Sundays and holidays:$250.00/day Replacement parts/supplies (i.e., special sealants, etc.), if necessary:as per Invoice Delivery of replacement parts (domestic), if any.Prepaid/Added to the invoice Delivery of replacement parts (international), if any.Collect

TRAVEL TIME All travel time from home base of operation to jobsite and return shall be charged in accordance with the above defined workday rates.Daily travel time to and from lodging will not be included and billed as part of the workday. STAND-BY TIME All time the Factory Representative is on stand-by or is available to work Monday through Friday, but is unable to due to reasons other than his own sickness or injury, shall be charged in accordance with the normal workday rates. TRANSPORTATION AND LIVING EXPENSES All transportation and living expenses during the service period from the time the Factory Representative leaves his base of operation until the time he returns shall be charged as defined above. RESPONSIBILITY The Factory Representative shall interpret the Company's drawings and data for the equipment and advise/assist the Customer regarding the sequence of steps and procedures for installation, start-up, dismantling, repairing and assembly of the equipment as the case may be. TheCustomershallsupply,attheirownexpense,alllabor,material,replacementparts,specialtools(otherthan Company-supplied tools and instruments required for unique procedures and/or collection of operating data), equipment cranes, rigging tools, outside balancing/machining and facilities required to perform the physical work on the equipment. L:\Turb\SERVICE\Forms\TURBLEX\Svc Rate 2009.doc 1635 W. Walnut Street Springfield, Missouri65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail:turblex@turblex.com Web Site:www.turblex.com ITEM A TURBLEX RECOMMENDED SPARE PARTS 1 SetCompressor Bearings 1 SetCompressor Seals/O-Rings 1 EachVariable Diffuser Actuator 1 EachMechanical Oil Pump 1 EachComplete Auxiliary Oil Pump Assembly including Motor, Coupling and Pump 1 SetOil Filter Elements/Filter 1 SetSTE- Compressor Special Tools DRIVE MOTOR 1 Set Bearing - Opposite Drive End (ODE) 1 SetBearing - Drive End (DE) INLET AIR FILTER HOUSING 1 SetCoarse Primary Filters/Unit 1 SetFine Secondary Filters/Unit NOTE:FOR ACTUAL SPARE PARTS, REFER TO COMPONENTS LIST UNDER TAB I. Z:\Submittal_O&M\Master_Sub\Item_A_GenInfo\Source_Docs\Recomm_Spare_Parts.doc OBSERVED PROBLEM PROBABLE CAUSE CHECK FOR OPERATOR RESPONSE1. Blower fails to start. 1a.1a. 1a.1b. Blow-off valve not fully open. 1b. Check blow-off valve status at LCP. 1b.1c. 1c. Verify switch position. 1c. Set the switch to NORMAL position.1d. NORMAL/TEST switch in TEST position. 1d. Verify switch position. 1d. Set the switch to NORMAL position.1e. Alarms not cleared. 1e. Check for alarms at LCP. 1e. Reset the alarm condition.1f. No power. 1f. 1f. Replace fuse and/or close breaker.1g. 1g. Verify time of last starts. 1g. Wait.1h. Discharge valve not closed. 1h. 1h. 2. 2a. High discharge pressure. 2a. 2a. Lower discharge pressure; verify flow.2b. IGV not at proper position. 2b. 2b.2c. IGV arm slipped on shaft 2c. IGV lever arm slipped on shaft. 2c. Verify match marks on IGV shaft. Recalibrate 4-20 mA.2d. VD not at proper position. 2d. 2d.2e. VD arm slipped on shaft. 2e. VD lever arm slipped on shaft. 2e. Verify match marks on VD shaft.3. 3a. Obstruction in piping or diffusers. 3a. Closed valves. 3a. Open valves to maximize flow.3b. Plugged diffusers. 3b.3c. Wrong tank level. 3c. Verify correct tank level.3d. Stuck check valve. 3d. 3d.3e. Discharge valve not fully open. 3e. 3e. Visually verify valve position.Reset limit switch.3f. Check power to valve operator. 3f.3g. 3g. Remove any debris.1High discharge pressure.Check for obstruction in valve, or operator's gears.Blower volume discharge low.Verify discharge pressure is within normal range.Visually evaluate diffuser pattern; attempt to spot plugged diffusers.Verify pressure upstream and downstream of check valve.Repair check valve if differential pressure data shows valve is faulty.Verify IGV position on compressor scale relative to readout on LCP.Verify electronics.Set to SERVICE mode and verify operation of IGV throughout range. Recalibrate 4-20 mA.Verify VD position on compressor scale relative to readout on LCP.Verify electronics.Set to SERVICE mode and verify operation of VD throughout range. Recalibrate 4-20 mA. GENERAL TROUBLESHOOTING GUIDEITEM ASet the SERVICE/NORMAL/TEST selector switch to SERVICE, and open the blow-off valve.Verify limit switches by using handwheel if necessary.NORMAL/SERVICE/TEST switch in SERVICE positionCheck at the breaker for blown fuse or breaker not engaged.Inlet guide vane open, possible failure of interlock.Check inlet guide vane open/closed status at LCP.Set the SERVICE/NORMAL/TEST mode to SERVICE, and close the inlet guide vane.Restart blocking; attempting more than two (2) starts per hour.Set the SERVICE/NORMAL selector switch to SERVICE and close the discharge valve. Verify valve operation and limit switch settings if closed LED does not illuminate on LCP.Discharge valve closed LED not illuminated.Check control panel indicators to see if "Discharge Valve Open" indicator is lit.Tighten any loose connections.Verify leads are connected properly.OBSERVED PROBLEM PROBABLE CAUSE CHECK FOR OPERATOR RESPONSE4. Blower surge. 4a. High discharge pressure. 4a. 4a. Check items under Section 3.4b. High inlet temperature. 4b. Verify inlet temperature is over 130oF. 4b.4c. Plugged inlet air filter. 4c. 4c.4d. 4d. Visually inspect connections. 4d.4e. Water in compressor volute. 4e. Verify operation of blow-off/discharge valve. 4e.5. 5a. Inlet temperature over 130oF. 5a. Verify with another thermometer. 5a. Run Compressor in the 60-80% range.5b. Inlet probe too close to volute. 5b. Verify inlet probe is not too close to volute. 5b. Relocate inlet probe.5c. Surge. 5c. Check points listed under Section 4. 5c. Check points listed under Section 4.6. 6a. High inlet temperature. 6a. Verify transmitter/sensor with thermometer. 6a. Replace the transmitter/sensor if faulty.6b. Operating off design. 6b. Verify IGV/VD position. 6b.6c. Discharge temperature over 275oF. 6c. Verify with thermometer. 6c.7. Motor overload. 7a. 7a. 7a. Reduce VD position.7b. Motor/blower malfunctions. 7b. Blower can be rotated easily. 7b.7c. Low input voltage. 7c. Verify 4160V input voltage. 7c. Correct under voltage situation.8. 8a. Auxiliary oil pump overload tripped. 8a. Verify touchpad warning light. 8a. Reset overload at MCC.8b. Auxiliary oil pump circuit breaker/fuses. 8b. Verify MCC. 8b.8c. Low oil level. 8c. View sight glass/level dipstick. 8c.8d. Auxiliary oil pump failure. 8d. Verify oil pump malfunction. 8d.9. 9a. Main oil pump loss of suction. 9a. Low pressure at main oil pump discharge. 9a. Prime main oil pump.9b. Lube oil piping failure. 9b. Inspect piping. 9b. Repair piping.Refill oil reservoir.9c. Low oil level. 9c. Verify oil level. 9c. Refill oil reservoir.9d. Main oil pump failure. 9d. Verify oil pump internals. Check valves operation.9d.2Lockout blower at MCC.Remove coupling guard.Blower and motor should rotate with approximately 200 ft/lb of torque applied to shaft.Low oil pressure during start/stop sequence.Reset circuit breaker, replace fuses, and verify operating current.Repair low oil level switches and add oil.Low oil pressure during operation.Lockout compresor and auxiliary oil pump.Verify oil pump internals.Operate blower in the 60-80% range if possible.Operate blower in the 60-80% range if possible.High inlet temperature; VD's at full open; discharge pressure high.Verify inlet temperature, discharge pressure, and VD position.Operate in SERVICE mode.Verify rotation.Rebuild oil pump.Pressure connections loose to surge switch.Tighten connections on blower and surge switch.High discharge air temperature.Remove plug at bottom of volute and drain.High inlet air temperature.Verify high discharge pressure check points listed under Section 3. GENERAL TROUBLESHOOTING GUIDEITEM AReplace air filter elements. Verify differential pressure meter operation.Verify differential pressure across air filter.Visually inspect air filter.Operate blower in the 60-80% range.If surging continues, discharge pressure should be reduced.OBSERVED PROBLEM PROBABLE CAUSE CHECK FOR OPERATOR RESPONSE10. 10a. Oil cooler fan not operating. 10a. Loss of power, motor overloads tripped. 10a. Reset.10b. Faulty temperature modulation. 10b. Temperature modulating valve closed. 10b. Repair valve.10c. Little or no water flow to cooler. 10c. 10c.11. 11a. Low ambient temperaure. 11a. Verify auxiliary oil pump is operating. 11a.11b. 11b. 11b. Repair valve.11c. Cold oil. 11c. Verify Oil Temperature. 11c.12. Oil filter bypass. 12a. Dirty oil filter. 12a. 12a. Replace filter cartridge.13. 13a. High oil temperature. 13a. 13a. Check oil cooler.13b. 13b. 13b. Reduce VD/IGV setting.13c. Temperature monitor problems. 13c. Verify temperature monitor operation. 13c.13d. Bearing problems. 13d. Abnormal log data. 13d.14. 14a. Low oil temperature. 14a. 14a. Verify modulating valve operation.14b. Coupling out of alignment. 14b. Verify coupling alignment. 14b.14c. Fault with vibration monitor. 14c. 14c. Notify TURBLEX.14d. Mechanical damage within the gearbox. 14d. Review logs for trends. 14d. Notify TURBLEX.14e. Impeller imbalance. 14e. Verify log for trends. 14e. Notify TURBLEX.15. 15a. Low motor lube oil level. 15a. Verify motor lube oil level. 15a. Add motor lube oil.15b. Contaminated motor bearing lube oil. 15b. Verify color and level of oil. 15b. Replace motor lube oil.15c. Wrong lubricant. 15c. Verify compatible lubricant. 15c. Replace motor lubricants per manufacturing recommendations.15d. Motor/blower out of alignment. 15d. Misalignment. 15d.Lockout drive motor and verify coupling alignment.15e. Failed motor bearing. 15e. Review operation logs and grease bearings.15e.Contact authorized motor service shop.3Verify RTD reading, temperature monitor operating, lights green.Temperature modulating valve stuck open.Verify temperature modulating valve operation.High differential pressure across oil filter via indicator on oil filter.Switch to SERVICE mode and operate auxiliary oil pump to raise temperature to at least 100oF and verify oil pressure.Stop machine and let cool.Start-up and record log data every 15 minutes until machine reaches stable temperature.Notify TURBLEX.Verify oil temperature is between 110oF-120oF.Lockout motor and verify coupling alignment.Blower/motor/proximity vibration high and abnormalnoise.Blower bearing high temperature.Verify that the oil temperature is between 110oF-120oF.Verify monitor operation by initiating self-test.High motor bearing temperature.High inlet temperature and high discharge pressure.Verify inlet temperature, discharge pressure, and motor current amps.Low oil temperature. GENERAL TROUBLESHOOTING GUIDEITEM ACheck water pressure, valve operation and position.Switch to SERVICE mode and start auxiliary oil pump if it has not automatically started.Low water pressure, faulty solenoid/temperature modulating valve, closed block valves.High oil temperature.OBSERVED PROBLEM PROBABLE CAUSE CHECK FOR OPERATOR RESPONSE16. 16a. 16a. 16a. Reduce VD/IGV setting.16b. High motor current. 16b. Verify motor loading. 16b. Review observed problem at motor overload.16c. Undervoltage/overvoltage. 16c. Verify 4160V input voltage on each phase. 16c. Correct voltage problem.16d. Connection resistance. 16d. Verify high voltage connections. 16d. Correct motor connection problem.16e. Internal motor damage. 16e. Review logs for evidence. 16e. Retain authorized motor repair shop.16f. High motor winding temperature. 16f. Verify motor winding temperature. 16f. Review motor winding problems.16g. Faulty RTD. 16g. Verify RTD functionality. 16g. Use spare RTD motor.16h. Faulty transmitter. 16h. Verify transmitter functionality. 16h. Contact Turblex for new transmitter.16i. Motor winding ventilation 16i. Verify free of debris. 16i. Contact authorized motor service shop.17. 17a. 17a. 17a.17b. Blow-off does not open. 17b. 17b. Visually verify valve position.Reset limit switch.17c. Discharge does not open. 17c. 17c. Visually verify valve position.Reset limit switch.4High motor winding temperature.High pressure, high inlet temperature, and VD/IGV at maximum.Verify inlet and ambient temperatures, discharge pressure, and VD/IGV position. GENERAL TROUBLESHOOTING GUIDEITEM AStopping; Sequence fail on shut-down (not shut-down in two (2) minutesVerify electronics.Set to SERVICE mode and verify operation of VD throughout range. Recalibrate 4-20 mA.Check control panel indicators to see if "Blow-Off Valve Open" indicator is lit.Check control panel indicators to see if "Discharge Valve Closed" indicator is lit.VD doesn't close. Verify VD position on compressor scale relative to readout on LCP.Document Name: 4607T-Item BRev B1635 W. Walnut Street Springfield, Missouri65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail:turblex@turblex.com Web Site:www.turblex.com ITEM B DESCRIPTION OF TURBLEX / STE COMPRESSOR The Turblex/STE compressor is of the single-stage, radial type driven by an electric motor through a speed increasing gear. The compressor is furnished as a complete unit with variable control guide vanes, integral speedincreasinggear,drivemotor,lubricationsystem,andvariousotheraccessoriesspecifiedbythe customer. All parts of the compressor are designed to minimize noise and vibration, and will be suitable for the service intended. Compressor Performance The compressor is designed in accordance with the customer's specifications for inlet capacity, discharge pressure, inlet temperature and pressure, and relative humidity. Compressor Case Housing The casing, rear plate, and flanges are made of close-grained cast iron ASTM A278, Class 30B, have a maximum design temperature of 400 F and a maximum design pressure of 50 psig. The compressor inlet is a slip ring design that connects to either an inlet silencer or inlet duct by a flexible band. The discharge flange is faced and drilled to ANSI 16.1, 125 pounds. All joints in the casing and rear plate are machined for close fit. The casing is vertically split and designed so that the impeller can be removed from the inlet side without removal of the casing. Lifting eyes capable of supporting the casing and a drain plug at the lowest point of the casing are provided. Impeller The impeller is of radial flow type with open and backward leaning blades that are machined from a forged hiduminium aluminum alloy material, ASTM B247 AA2618 (Al Cu2 Mg1.5 Fe1 Ni1, Rolls Royce Aircraft Alloy No. 58). The impeller is attached to the shaft by a shrink-fit and locknut arrangement, and is statically and dynamically balanced. The axial gap between the impeller and the casing is adjustable by means of shims. Variable Control Guide Vanes KA S Compressor:A single guide van machine with adjustable discharge variable diffuser vanes (VD) for capacity control.The vanes are multi-leaf, pivoted, and attached to permanently lubricated sleeve bearings.The VD assembly is mounted integral with the compressor.The assembly includes a lever/scale arrangement for local indication of vane position, an electric actuator with a built-in position feedback for remote indication of vane position, and two adjustable max/min position limit switches. Integral Gearbox The gear housing is made of high-grade cast iron that is sufficiently rigid to maintain the shaft positions under maximumloads.Thegearhousingassembliesaremachinedtoclosetolerancesforbearingfits,gear alignment, and oil tightness. All gears are manufactured according to AGMA 6025-C90, to minimum AGMA quality number of no less than 12, as specified in AGMA 2000/A88. The gear is rated for continuous duty with a minimum service factor of at least 1.8 at ambient temperatures within the customer's operating conditions in accordancewithAGMA421.06.Allexposedmachinedsurfacesarecoatedwithacorrosion-resistant compound before shipment. GL Series Gearbox: The speed increasing gear is a one-stage increase, helical, parallel shaft type.The gear housing is vertically split. ITEM B DESCRIPTION OF TURBLEX/HV-TURBO COMPRESSOR (REFER TO NAMEPLATE DATA SHEET FOR COMPRESSOR MODEL SUPPLIED) Shafts and Seals The shafts are made of high quality alloy steel, accurately machined, case hardened, and ground to size. The shaft seals are non-contact, multi-point labyrinth type with small clearances and sufficient touch points to minimize air leakage out of or into the casing while the compressor is running in the specified operating range or during shutdown. The seals are operated dry and are suitable for any variations in pressure conditions that may occur during start-up, normal operation, and shutdown. Bearings GL Series Gearbox:The drive shaft radial bearings are cylindrical journal bronze bearings. The drive shaft thrust bearings are multiple segment, double-acting bronze bearings designed for thrust in both directions. The pinionshaftradialbearingsaremultiplesegmentbabbittedbronzebearingsdesignedtosuppress hydrodynamic instabilities and provide sufficient damping to limit motor vibrations. The pinion shaft thrust bearings are multiple segment, tapered land bronze bearings designed for thrust in both directions. The radial and thrust bearings are pressure lubricated and designed for fully hydrodynamic lubrication with sufficient oil film thickness under all operating conditions. Lubrication System A complete lube oil system is provided with each compressor unit. The system is capable of supplying clean oil at suitable pressure and temperature to lubricate the compressor gears and bearings. All components of thelubricationsystemtypicallyareinstalledand/orintegralwiththecompressorunitbaseplate.The components are arranged to permit ease of accessibility for operation, maintenance, inspection, and cleaning.

GL Series Gearbox: The lube oil system consists of a reservoir in the compressor unit baseplate, a gearbox driven main oil pump, an electric motor driven auxiliary oil pump, an oil cooler, a thermostatic control valve, an oilfilter,andmiscellaneousappurtenances.Thethermostaticcontrolvalvewillmaintainconstantoil temperature. Oil Pumps Theoilpumpsarepositivedisplacementtype.Typically,onemainandoneauxiliarypumpareprovided, except for the GK series gearbox.The motors for electrically driven pumps are TEFC type; the horsepower is rated for the application and usually requires 460 VAC. Oil Cooler A customer specified oil cooler is provided to remove excess heat from the lube oil circuit. The two primary types of oil coolers used by Turblex are the shell and tube water/oil cooler, and the fin and tube air/oil cooler. Oil Reservoir The oil reservoir is integral to the compressor baseplate. The interior of each oil reservoir is de-scaled and rust proofed by the application of a permanent coating of the manufacturers standard. The equipment attached to the top of the reservoir will be mounted by means of pads to ensure that no tapped holes will extend into the reservoir. All covered openings are gasketed. Reservoirs will be baffled to minimize air entrainment and to isolate foam. The reservoir is equipped with a suitably sized vent and breather. The oil reservoir will have a minimum working capacity of three minutes retention time based upon the mechanical oil pump flow. ITEM B DESCRIPTION OF TURBLEX/HV-TURBO COMPRESSOR (REFER TO NAMEPLATE DATA SHEET FOR COMPRESSOR MODEL SUPPLIED) Oil Filter GL Series Gearbox:The oil filter is a full flow, replaceable cartridge type, capable of removing particles 9 microns in diameter with 98.7% efficiency.The clean oil filter pressure drop shall not exceed 5 psi at the design temperature and flow.A duplex (two bowl) or simplex (single bowl) filter is supplied in accordance with the customers specification.The filter element collapse pressure is twice the bypass pressure.The minimum bypass pressure is 35 psid.A visual indicator is provided to indicate filter condition and filter replacement. . Coupling GL Series Gearbox: The motor-to-compressor coupling is a forged steel, flexible, spacer type with a design safety factor of at least 1.5 under all operating conditions. The coupling spacer is of sufficient length to permit the dismantling of the compressor without removing the compressor housing or the electric motor. Baseplates Thecompressorunitisfurnishedwithabaseplateofadequatesizetosupportthecompressor,motor, lubricating system, and accessories. The baseplate is constructed of fabricated steel and is provided with four lifting lugs. The baseplate is sufficiently rigid to permit lifting the unit, with all equipment mounted, by the four lifting lugs using a four point lift, without distorting or damaging the baseplate or components mounted to the baseplate. Z:\Submittal_O&M\Master_Sub\Item_B_CompressorInfo\Source_Docs\Descrip_of_Tublx_Compressor.doc 1635 W. Walnut Street Springfield, Missouri65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail:turblex@turblex.com Web Site:www.turblex.com ITEM B VARIABLE DIFFUSERSDESCRIPTION OF OPERATION Single-stage HV-Turbo Type S compressors have the unique capability of turndown from 100 to 45% of capacity utilizing variable diffusers (VD) in concert. This device, used independently, effectively controls capacity, however, maximum efficiencies are achieved through utilization of integrated automatic controls applied to machines equipped with variable diffusers (VD). Variable Diffusers - Variable diffusers are a series of aerodynamic vanes around the discharge of the impeller that essentially act as an extension of the impeller blades.The variable diffusers alter the radial component of the velocity of the air exiting the impeller.Thus, rather than throttling, like the inlet guide vanes, the variable diffusers actually alter the flow direction of the air exiting the impeller.As a result, compressor efficiency is not significantly affected as the capacity is reduced. The diffuser vanes further, streamline the flow of air in the compressor internals and volute and reduce losses due to turbulence.More of the velocity energy of the air is then available at the blower outlet.The direction of rotation, shape and spacing of the vanes are such that the capacity ofthemachinecanbevariedfrom100%toapproximately45%withvirtuallynodecreaseof efficiency. 1635 W. Walnut Street Springfield, Missouri65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail:turblex@turblex.com Web Site:www.turblex.com ITEM B SURGING AND RECIRCULATION Surging is one of the most discussed and most feared foibles of centrifugal and other non-positive displacement compressors. Surging and recirculation occur when the adiabatic head generated by the compressor is less than is needed to maintain a uniform, forward flow of air through the impeller.If the air flow rate reduces belowacertainlevel,thedirectionsoftheairflowinsidetheimpelleraresodifferentfromthe angles of the impeller blades, that air flow breaks down completely. Whenthisoccurs,compressedairfromdownstreamofthecompressorexpandsthroughthe impeller in surges, giving rise to the characteristic surging noise. Othereffectsofsurgingaretoproducerapidchangesinthemechanicalloadontherotating impeller and drive components, and to produce momentary pressurizing in the compressor inlet. Siemens Turbomachinery Equipment (STE) uses the pressure rise in the inlet to initiate a surge alarm and to stop the compressor before serious mechanical damage occurs. Recirculation will occur before full scale surging and results in discrete streams of hot air from the compressor outlet channeling into the inlet through low flow surfaces of the impeller.This results in a rapid temperature rise in the inlet of the compressor. Unlessitischecked,continuedrecirculationcanresultinthermaldamagetothecompressor internals.A temperature sensor in the inlet is used by STE to shut down the compressor if the temperature in the inlet rises above 130oF. Surging and recirculation result from either a decrease in the adiabatic head being generated by the impeller or an increase in the system pressure ratio to levels above the design pressure ratio. Pressure Ratio =Absolute outlet pressure = P2 Absolute inlet pressure P1 Factors which can upset the pressure ratio are increases in system pressure downstream of the compressor or decreases in system pressure at the inlet to the compressor. Either can be caused by excessive fouling or throttling. A reduction in the adiabatic head being generated by the compressor can result from: increased inlet air temperature increased relative humidity of the inlet air reduced operating speed of the compressor Itisimportantthentodesigncompressorsfortheworstconditionsofpressureratio,inletair temperature, relative humidity and flow which they will be expected to endure in service. 2 Item B Because surging and recirculation occur primarily due to a reduction in flow rate, even compressors suchastheSTETypesSandSV,whichcontrolairflowwithoutthrottling,arelimitedintheir turndown capacity.For STE that is usually at 45% of design flow.For other types of compressors, which rely on throttling for flow control, the turn-down limit could be as high as 65% of design flow and such a limited turn-down gives rise to other, more serious problems in process control where more than one compressor is in service. Z:\Submittal_O&M\Master_O&M\Item_B_CompressorInfo\Source_Docs\Surge.doc Item BIndgangsakselomdrejningstal (o/m) AntriebswelleDrehzahl (upm)Driveshaftspeed (rpm)Opstartsmoment (Nm) Anlaufmoment (Nm) Torque(Nm)0 500 1000 1500 2000 2500 3000 3500050010001500200025003000350040004500 >10 rad/s^2HVTURBO VerdichterAnlaufmomentkurveKA66 S GL400Dato:010808:09:18:41HVTURBO compressorSpeedtorque curveKA66 S GL400Dato:010808:09:18:41HVTURBO kompressorOpstartsmomentkurveKA66 S GL400Dato:010808:09:18:41 Pbaro= 0.8980 (Bar) Tmin=281.15 (K) Qmin = 31589. (m3/h)I=wk2= 34.3(kg*m2) GD2 =137.2(kg*m2) Sign:__________Item B1635 W. Walnut Street Springfield, Missouri65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail:turblex@turblex.com Web Site:www.turblex.com ITEM C LOCAL CONTROL PANEL (LCP) OPERATION DESCRIPTION FOR COMPRESSORS WITH GL SERIES GEARBOX AND SINGLE VANE CONTROL The following is the basic concept for controlling the Turblex/HV-Turbo compressor with variable diffusers. 1 - Compressor In Stand-by/Read For Start Conditions Before a compressor may be started, the following stand-by conditions must be established: -VD [Variable Diffusers] closed (in minimum) -BOV [Blow-Off Valve] opened -DV [Discharge Valve] closed-No alarms -Reservoir oil temperature above 50F If the above conditions are not met, start is inhibited at the LCP (Local Control Panel). 2 - Start Sequence The start sequence may be initiated by pushing the "Blower Start" button on the Operator Interface, or by a start/stop signal from a MCP (Master Control Panel) or plant control system, where applicable. -Theauxiliaryoilpumpstartsa2-minutepre-lubricationcycle;theoilpressureattheinlettothe gearbox must be established (higher than 15 psig) within 1 minute of the start sequence.If the oil pressure setpoint is not achieved in 1 minute, the start sequence is terminated on a Low-Low Oil Pressure Alarm (Sequence Failure). -At the end of the 2-minute pre-lubrication cycle, the LCP gives a Start/Stop (dry contact) signal to the Main Motor Starter to energize the drive motor. -The LCP receives a feed back signal (dry contact) from the Main Motor Starter (normally no later than 20 seconds after the start signal has been given); this confirms that the drive motor is running.If the startverificationisnotreceivedin20seconds,thestartsequenceisterminatedonaNoMotor Feedback Alarm (Sequence Failure). -After the motor feed back signal is received, the DV starts to open and a 5-minute BOV "guardian" timer starts. -Theoilpressureatthemechanicaloil pump must be established (higher than 29 psig) within 20 secondsafterthemotorfeedbackisreceived.Iftheoilpressuresetpointisnotachievedin20 seconds, the start sequence is terminated on a Low Oil Pressure Alarm (Sequence Failure). If the oil pressure setpoint is achieved in 20 seconds, the auxiliary oil pump will run for another 10 seconds before going off-line. -After the auxiliary oil pump has gone off-line, and the DV is opened, the BOV begins to close slowly via a pulsed motion (closing time normally between 30-120 seconds). Example:Travel time = 30 seconds 2 seconds "on", 5 seconds "off" 105 seconds closing time -IftheBOVisnotclosedwhenthe5-minuteBOVguardiantimerexpires,thestartsequenceis terminated on a Start Taking Too Long Alarm (Sequence Failure). -After the BOV is closed the VD is ready for operational control. Document Name: 4607T_LCP_Oper_Descrp_Rev 0 ITEM C LOCAL CONTROL PANEL (LCP) OPERATION DESCRIPTION 2 2 - Start Sequence Continued -The start sequence is finished. During the start sequence, the surge monitor is bypassed until the auxiliary oil pump has gone off-line. 3 - Remote/Local Operation -When the LCP is set in the Local mode, the VD is positioned manually by open/close controls on the operator interface.Press VD open to increase flow and VD close to decrease flow. -When the LCP is set in the Remote mode, control of the VD is based on an increase or decrease capacity signal sent from a MCP or plant control system, where applicable. 4 - Stop Sequence Normal Stop: The stop sequence may be initiated by pushing the "Blower Stop" button on the Operator Interface, or by dropping the start/stop signal from a MCP or plant control system, where applicable.-The VD moves to the minimum position and a 120-second stop timer starts. -When the VD is at the minimum position, the BOV opens fast (nominal 15 seconds). -When the BOV is opened, the DV closes. -When the DV (motorized) is closed, or the 120-second timer expires, the start/run signal will drop to the Main Motor Starter to stop the drive motor.-After the motor feedback signal is lost, the auxiliary oil pump starts the 5-minute post-lube cycle. -5 minutes after the motor feedback signal is lost, the auxiliary oil pump stops. -The stop sequence is finished. "Soft" Stop: See 5, below, for conditions that initiate a soft stop. -The VD moves to the minimum position, the BOV opens fast, and an 8-second stop timer starts. -When the BOV is opened or the 8-second timer has run out, the start/run signal will drop to the Main Motor Starter to stop the drive motor. -After the motor feedback signal is lost, the auxiliary oil pump starts the 5-minute post-lube cycle, and the DV closes. -5 minutes after the motor feedback signal is lost, the auxiliary oil pump will stop. -The stop sequence is finished. Emergency Stop: See 5, below, for conditions that initiate an emergency stop. -The start/run signal will drop to the Main Motor Starter to stop the drive motor, the BOV opens fast, the DV closes, and the VD moves to the minimum position. -After the Main Motor Starter feedback signal is lost.The auxiliary oil pump starts the 5-minute post-lube cycle. -5 minutes after the motor feedback signal is lost, the auxiliary oil pump stops. -The stop sequence is finished. ITEM C LOCAL CONTROL PANEL (LCP) OPERATION DESCRIPTION 3 4 - Stop Sequence Continued All of the above stop sequences place the blower in "stand-by" position with the correct positioning of all components for re-start. During any stop sequence, the surge control unit and vibration alarms will be bypassed. 5 - Alarms and Shut-Downs (Trips) There are two ways to stop the blower under abnormal conditions: A.A "Soft" stop is initiated when any of the following trip conditions occur: "High Oil Temperature""High Inlet Air Temperature""Surge""High Drive Motor Amps""High Blower Bearing Temperature""High Motor Bearing Temperature"High Motor Winding TemperatureSome mild surging may occur during a soft stop. B.An "Emergency" is initiated when the "Emergency-Stop" button is pushed or when any of the following trip conditions occur: "Low Oil Pressure""PLC Failure"No Motor Feedback at StartLost Motor Feedback During Normal RunStart Sequence Taking Too LongMotor not Stopped in 2 Minutes of Stop Sequence"High Blower Casing Vibration"Some surging will occur during an emergency stop. If any of the above alarm/trip conditions occurs, a common alarm signal will be available to a MCP or plant control system, where applicable.If the OIT (Operator Interface) fails, Turblex recommends stopping the machine; do not continue operation.If the PLC fails, the unit will drop all the output/input signals and the unit will shut-down. All the alarms must be re-set or acknowledged one alarm at a time.Furthermore, the alarms will disappear after the reason for the alarm is corrected. 6 - Drive Motor High Amp Warning/Alarm Operation -If the drive motor begins pulling 98% of its rated amperage during normal operation, the LCP will automatically prevent the VD position from being increased further. -If the drive motor begins pulling 102% of its rated amperage during normal operation, the LCP will automatically decrease theVD position to decrease the motor amperage below its alarm setpoint. -If the drive motor amperage continues to increase to 105% of its rated amperage, and a 45 second timer starts,the LCP will then initiate a "soft stop sequence. 7 Restart Blocking If the blower is started and stopped more than two (2) times in less than an hour from the first start, the LCP will inhibit the next start attempt on a Restart Blocking Alarm until that hour has ended. 8 Zero Speed Switch (Optional, included if specified)When the blower is stopped, the zero speed switch is activated.Upon detection of rotation, the auxiliary oil pump will start to keep the bearings lubricated.The auxiliary oil pump will run for another 2 minutes after the Zero Speed Alarm is cleared. ITEM C LOCAL CONTROL PANEL (LCP) OPERATION DESCRIPTION 4 9 - Mechanical & Auxiliary Oil Pump Operation Upon initiation of compressor start, the auxiliary oil pump is started along with a 60-second timer to allow the oil pressure to rise above the PSLL setpoint. If the oil pressure is not greater than the PSLL setpoint within 60 seconds, the start sequence is terminated on a Low-Low Oil Pressure Alarm. Upon start of the drive motor, a 30-second guardian timer is initiated to allow the mechanical oil pump to build oil pressure above the PSL setpoint.If the oil pressure is not greater than the PSL setpoint within 20 seconds, the start sequence is terminated on a Low Oil Pressure Alarm. At a time between 20 and 30 seconds after the drive motor is started and the oil pressure is greater than the PSL setpoint, the auxiliary oil pump shall go off-line.Once oil pressure above the PSL setpoint has been achieved, the drop of oil pressure below PSL and/or PSLL will initiate the start of the auxiliary oil pump and an emergency stop. When the compressor is stopped, the oil temperature is continuously monitored.If the oil temperature falls below the Low Oil Temperature Alarm setpoint (60F), the auxiliary oil pump will start to provide a heat source to the oil and will remain energized for 2 minutes after the oil temperature has reached above the Low Oil Temperature Alarm setpoint.If the oil temperature falls below the Low-Low Oil Temperature Alarm setpoint (50F), the LCP will inhibit compressor start until the temperature rises above the Low-Low Oil Temperature Alarm setpoint. 10 Service-Normal-Test Switch Operation There is a software switch displayed on the Operator Interface called the "Service-Normal-Test" switch.With this switch in the "Test" position, the dry contact signal for start to the Main Motor Starter is bypassed, and a simulated feedback signal from the Main Motor Starter is created so a start-up procedure can be simulated without running the drive motor.When the Service-Normal-Test switch is in the Service position, the following components can be manually "exercised" or turned on and off from the Operator Interface: a.Manual start/stop of electric oil pump b.Manual open/close of BOV c.Manual open/close ofVD d.Manual open/close of oil cooler solenoid valve (water cooler) During normal operation, the Service-Normal-Test switch shall be placed in the normal position.While the compressor is running, the VD control can be switched from local to remote (LCP Control or MCP Control), or conversely. 11 Automatic Vane Exercise Every 12 hours that the blower is setting idle (not running), the processor will automatically exercise the VD from their full closed position to their full open position, and return them to their closed position.This helps preventunnecessarymaintenanceduetotheunitsittingidlefor long periods of time.The LCP will also automatically recalibrate the VDs if out of calibration. 12 Automatic Calibration of VD There is a software button displayed on the Operator Interface called the R/I Automatic Calibration.Push this button to automatically calibrate the VD scales in the PLC to the mechanical scales on the blower.This button is disabled when the blower is in start sequence or on-line. Z:\Submittal_O&M\Master_Sub\Item_C_OperationDesc\Source_Docs\LCP_Oper_Descrp_GL_GB_V.doc 1635 W. Walnut Street Springfield, Missouri65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail:turblex@turblex.com Web Site:www.turblex.com Turblex 4607T Local Control Panel (LCP) Interface / Screens: Please note: LCP operator interface / screens will be available in the Final Turblex Operation and Maintenance Manual. ITEM C1635 W. Walnut Street Springfield, Missouri65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail:turblex@turblex.com Web Site:www.turblex.com ITEM C OPERATING RESTRICTIONS (REFER TO NAMEPLATE DATA SHEET FOR GEARBOX MODEL SUPPLIED) 1.Blower cannot be started under load. 2.Blower cannot start or stop if another blower is starting/stopping. 3.Maximum lubricating oil temperature is 160F for GA, GB, GC, and GL series gearboxes, 230oF for GK series gearboxes. 4.Minimum lubricating oil temperature is 50F for GA, GB, GC, and GL series gearboxes. 5.Maximum inlet air temperature is 130F. 6.Proper oil level in the oil reservoir or oil sump must be maintained. 7.Minimum lubricating oil pressure downstream of the oil filters is 15 psig (not applicable to GK2/B3 gearbox). 8.Minimum lubricating oil pressure at the mechanical pump discharge is 20 psig (applies to GB and GL series gearboxes, only). 9.Power must be left on to LCP when the blower is not operating, except for maintenance. 10.Blower safety shutdowns must not be bypassed. 11.Program in PLC must not be changed without written permission from Turblex. 12.Blower rotation is unidirectional depending on the gearbox model: 13.Motorstartingcapabilityatthemotorstarterormotorcontrolcenter(MCC)mustbedeletedor disabled.Start must be initiated from the local control panel (LCP). 14.The discharge check valve is to be installed as close to the discharge cone as possible.Turblex recommends the discharge check valve be installed in the horizontal position.If it is not installed in the horizontal position, please notify Turblex.The hinge post must be in the vertical position.A pipe spool (minimum one pipe diameter) must be installed between the check valve and the discharge valvetoallowclearanceforthevalveplatestoopen.PleaserefertoItemAforInstallation Instructions for Field Mounted Components. NOTE:If safety shutdowns are bypassed and/or PLC program is changed without written permission from Turblex, the Warranty will be VOIDED. Z:\Submittal_O&M\Master_Sub\Item_C_OperationDesc\Source_Docs\Operating Restrictions CCW -1.doc COUNTER-CLOCKWISE ROTATION (looking at the blower input shaft) GA200, GA250, GB225,GK200, GL210, GL225, GL285, GL315, GL400 and GL500 REV DATE:INSTRUMENT SETPOINTS (PAGE 1)DESCRIPTION ACTION US SETPOINT SI SETPOINT OIT DESCRIPTION NOTATION GAGB GC GK GLOTHERSINLET GUIDE VANE POSITION INLET GUIDE VANE POSITION 1 N.N SCALE SCALE INLET GUIDE VANE POSITION IGVVARIABLE DIFFUSER VANE POSITION VARIABLE DIFFUSER VANE POSITION 1 N.N SCALE SCALE VARIABLE DIFFUSER VANE POSITION VDBLOWER DIFFERENTIAL PRESSURE TRANSMITTER BLOWER DIFFERENTIAL PRESSURE TRANSMITTER 2 N.NN PSID kPa D BLOWER DIFFERENTIAL PRESSURELUBE OIL SYSTEMDESCRIPTION ACTION US SETPOINT SI SETPOINT OIT DESCRIPTIONOIL PRESSURE RELIEF VALVE CRACKING SETPOINT BYPASS TO RESERVOIR (NOTE 11 et.al.) S 120 PSI 827 kPa G R X X X XOIL FILTER BYPASS VALVE BYPASS FILTER S 35 PSID 241 kPa G R X X X X XOIL FILTER BYPASS VALVE BYPASS FILTER S 50 PSID 345 kPa G R GL500OIL FILTER DIFFERENTIAL PRESSURE (H) ALARM 1 1/0, N.N 25 PSID 172 kPa G OIL FILTER DIFFERENTIAL PRESSURE - ALARM R XOIL FILTER DIFFERENTIAL PRESSURE (H) ALARM 1 1/0, N.N 35 PSID 241 kPa G OIL FILTER DIFFERENTIAL PRESSURE - ALARM R X X X XOIL TEMPERATURE REGULATING VALVE WATER FLOW MODULATION - 120 F 49C NA X X X XOIL TEMPERATURE REGULATING VALVE HOT/COLD OIL MIX MODULATION - 120 F 49C NA X X X XOIL COOLER FAN MOTOR TURN FAN ON/OFF (NOTE 11 et.al.) 1/0 105 / 95 F 41 / 35C OIL COOLER FAN ON / OFF R/F X X X XOIL COOLER FAN MOTOR GK200 & GK190 TURN FAN ON/OFF 1/0 158 / 131 F 70 / 55C OIL COOLER FAN ON / OFF R/F XOIL RESERVOIR TEMPERATURE (L/LL) ALARM & RUN AUX. PUMP / START INHIBIT 0 N. 60 / 50 F 16 / 10C LOW OIL TEMPERATURE - START INHIBIT F X X X XOIL RESERVOIR TEMPERATURE (H/HH) ALARM / TRIP 0 N. 150 / 160 F 66 / 71C HIGH OIL RESERVOIR TEMPERATURE - ALARM / TRIP R X X X XOIL RESERVOIR TEMPERATURE (H/HH) GK200 ALARM / TRIP 0 N. 212 / 220 F 100 / 104C HIGH OIL RESERVOIR TEMPERATURE - ALARM / TRIP R XOIL RESERVOIR TEMPERATURE (H/HH) GK190 without OIL COOLER ALARM / TRIP 0 N. 202 / 212 F 94 / 100C HIGH OIL RESERVOIR TEMPERATURE - ALARM / TRIP R XOIL RESERVOIR TEMPERATURE (H/HH) GK190 with OIL COOLER ALARM / TRIP 0 N. 165 / 176 F 74 / 80C HIGH OIL RESERVOIR TEMPERATURE - ALARM / TRIP R XOIL PRESSURE (L/LL) TRIP 1 1/0, N.N 29 / 15 PSIG 200 / 103 kPa G LOW OIL PRESSURE - TRIP F X XOIL PRESSURE (L/LL) TRIP 1 1/0, N.N 20 / 15 PSIG 138 / 103 kPa G LOW OIL PRESSURE - TRIP F X XOIL PRESSURE (L) TRIP 1 1/0, N.N 15 PSIG 103 kPa G LOW OIL PRESSURE - TRIP F XOIL PRESSURE (H) ALARM 1 N.N 150 PSIG 1034 kPa G HIGH OIL PRESSURE - ALARM R X X X X XINLET / DISCHARGE TEMPERATURE AND PRESSUREDESCRIPTION ACTION US SETPOINT SI SETPOINT OIT DESCRIPTIONINLET TEMPERATURE (H/HH) ALARM / TRIP 0 N.N 120 / 130 F 49 / 54C HIGH INLET AIR TEMPERATURE - ALARM / TRIP RINLET 1ST STAGE FILTER DIFF PRES (H) ALARM 2 1/0, N.NN 1" WC 0.25 kPa D HIGH INLET AIR PRE-FILTER DIFF PRESS - ALARM RINLET 2ND STAGE FILTER DIFF PRES (H) ALARM 2 1/0, N.NN 1.5" WC 0.37 kPa D HIGH INLET AIR FILTER DIFF PRESS - ALARM RINLET DIFFERENTIAL PRESSURE (H) ALARM 2 1/0, N.NN 4.2" WC 1.04 kPa D HIGH INLET AIR OVERALL DIFF PRESS - ALARM RDISCHARGE TEMPERATURE (H/HH) ALARM / TRIP 0 N. NOTE 1 NOTE 3 OUTLET AIR TEMPERATURE - ALARM / TRIP RDISCHARGE PRESSURE (H/HH) ALARM / TRIP 1 N.N NOTE 2 NOTE 4 OUTLET AIR PRESSURE - ALARM / TRIP RNOTE 1:ALARM = DESIGN PRESSURE (PSIG) * 14 + MAX. INLET TEMP. (F); TRIP = ALARM + 10 FNOTE 2:ALARM = DESIGN PRESSURE (PSIG) + 0.1 PSIG; TRIP = ALARM + 0.1 PSINOTE 3: ALARM =DESIGN PRESSURE (kPa G) * 1.13 + MAX INLET TEMP (C); TRIP = ALARM + 6NOTE 4:ALARM = DESIGN PRESSURE (kPa G) + 0.7 kPa G; TRIP = ALARM + 0.7 kPa GNOTE 5: For Bently Nevada systems, 20/25 mils pp, this is the limit of the detection system.NOTE 6: Temperature degree symbol, type ALT+0176 or ALT+248 from the NUMLOCK keyboardNOTE 7: GA / GL GEARBOXESNOTE 8: GC GEARBOXESNOTE 9: DE - Drive End, ODE - Opposite Drive End of Motor or BlowerNOTE 10: IMP END - Impeller End, OPP IMP END - Opposite Impeller EndNOTE 11: Num Dec. Places, i.e. 2=N.NN: S-Switch, 1/0-ON/OFF: 1/0, N.N is either switch or transmitterNOTE 12: As Required for Job Specific Vibration SystemNOTE 13: See Project Manager for dip switch setting documentationNOTE 14: Reference Document for Terminology: Standard_Vibration_Terminology2/28/2008GK 190 OIL RESERVOIR TEMPERATURE TRANSMITTER RANGE(NOTE 13)DIP SWITCH SETTINGS 0 N. X -ITEM CRISING / FALLINGRISING / FALLING GEARBOX SERIESRNUM. DEC. PLACESNUM. DEC. PLACESRISING / FALLING NUM. DEC. PLACESN.NNN32 / 392 F 0 / 200CZ:\Submittal\Master\Item_C_OperationDesc\Source Docs\Instrument_Setpoints.Feb 2008.xls Printed: 12/5/2008REV DATE:INSTRUMENT SETPOINTS (PAGE 2)BLOWER / MOTOR TEMPERATURE (Note 9,10,14)DESCRIPTION ACTION US SETPOINT SI SETPOINT OIT DESCRIPTION NOTATION GAGB GC GK GLOTHERSBLOWER STRAIGHT BABBIT BLWR HS SHAFT IMP END BRG TEMP - ALARM / TRIP Blwr HIEJOURNAL BEARING TEMPERATURE BLWR HS SHAFT OPP IMP END BRG TEMP - ALARM / TRIP Blwr HOIEBLOWER INPUT SHAFT STRAIGHT BABBIT BLWR SS SHAFT ODE BRG TEMP - ALARM / TRIP Blwr SODEJOURNAL BEARING TEMPERATURE BLWR SS SHAFT DE BRG TEMP - ALARM / TRIP Blwr SDEBLOWER TILT-PAD JOURNAL BLWR HS SHAFT IMP END BRG TEMP - ALARM / TRIP Blwr HIEBEARING TEMPERATURE BLWR HS SHAFT OPP IMP END BRG TEMP - ALARM / TRIP Blwr HOIEBLWR HS SHAFT IMP END BRG TEMP - ALARM / TRIP Blwr HIEBLWR HS SHAFT OPP IMP END BRG TEMP - ALARM / TRIP Blwr HOIEBLOWER HIGH SPEED SHAFT THRUST BEARING TEMPERATURE ALARM / TRIP 0 N. 194 / 203 F 90 / 95C BLWR HS SHAFT THRUST BRG TEMP - ALARM / TRIP Blwr HZ R X X X XMOTOR SLEEVE BEARING TEMPERATUREALARM / TRIP 0 N. 194 / 203 F 90 / 95C MOTOR DE / ODE BRG TEMP - ALARM / TRIP Mtr ODE / DE RMOTOR ANTI-FRICTION BEARING TEMPERATURE ALARM / TRIP 0 N. 212 / 221 F 100 / 105C MOTOR DE / ODE BRG TEMP - ALARM / TRIP Mtr ODE / DE RMOTOR WINDING TEMPERATURE ALARM / TRIP 0 N. 320 / 329 F 160 / 165C MOTOR "A/B/C" WINDING TEMP - ALARM / TRIP Mtr W RMOTOR AMPSDESCRIPTION ACTION US SETPOINT SI SETPOINT OIT DESCRIPTIONMOTOR AMPS LIMIT VD OPENING 0 N. MOTOR AMP LIMIT - LIMITING VD RMOTOR AMPS REDUCE VD 0 N. MOTOR AMP LIMIT - REDUCING VD RMOTOR AMPS TRIP 0 N. HIGH MOTOR AMPS - TRIP > (TRIP DELAY TIMER LENGTH) RMOTOR AMPS TRIP DELAY TIMER 0 N. MOTOR TRIP DELAY TIMER NAVIBRATION (Note 9,10,14)DESCRIPTION ACTION US SETPOINT SI SETPOINT OIT DESCRIPTION NOTATION 2 5 10 22 44 66 80 100BLOWER HIGH SPEED SHAFT RADIAL VIBRATION (X-Y) (NOTES 7,8) ALARM / TRIP 2 N.NN 3 / 5 MILS-PP 0.08 / 0.13 mm-pp BLWR HS SHAFT IMP END VIBRATION X / Y - ALARM / TRIP Blwr HIE R X X X X X X X XBLOWER HIGH SPEED SHAFT RADIAL VIBRATION (X-Y) (NOTE 7) ALARM / TRIP 2 N.NN 3 / 5 MILS-PP 0.08 / 0.13 mm-pp BLWR HS SHAFT OPP IMP END VIBRATION X / Y - ALARM / TRIP Blwr HOIE R X X X X X X X XBLOWER SLOW SPEED SHAFT RADIAL VIBRATION (X-Y) (NOTE 7) ALARM / TRIP 2 N.NN 3 / 5 MILS-PP 0.08 / 0.13 mm-pp BLWR SS SHAFT ODE VIBRATION X / Y - ALARM / TRIP Blwr SODE R X X X X X X X XBLOWER SLOW SPEED SHAFT RADIAL VIBRATION (X-Y) (NOTE 7) ALARM / TRIP 2 N.NN 3 / 5 MILS-PP 0.08 / 0.13 mm-pp BLWR SS SHAFT DE VIBRATION X / Y - ALARM / TRIP Blwr SDE R X X X X X X X XBLOWER HIGH SPEED THRUST POSITION PLUS (Z) ALARM / TRIP 2 N.NN 15 / 20 MILS-PP 0.38 / 0.51 mm-pp BLWR HS SHAFT THRUST Z POSITION (+) ALARM / TRIP Blwr HZ R X X X X X X X XBLOWER HIGH SPEED THRUST POSITION MINUS (Z) ALARM / TRIP 2 N.NN - 15 / 20 MILS-PP 0.38 / 0.51 mm-pp BLWR HS SHAFT THRUST Z POSITION (-) ALARM / TRIP Blwr HZ R X X XBLOWER HIGH SPEED THRUST POSITION MINUS (Z) (NOTE 5) ALARM / TRIP 2 N.NN- 25 / 30 MILS-PP 50.64 / 0.76 mm-pp BLWR HS SHAFT THRUST Z POSITION (-) ALARM / TRIP Blwr HZ R X X X X XBLOWER GEARBOX VIBRATION ALARM / TRIP 2 N.NN 0.2/0.3 IPS-PK 5.1 / 7.6 mm/s-pk BLOWER GEARBOX VIBRATION - ALARM / TRIP Blwr GB R X X X X X X X XBLOWER GEARBOX VIBRATION ALARM / TRIP 1 N.N 13 / 15 G'S 13 / 15 G's-pk BLOWER GEARBOX VIBRATION - ALARM / TRIP Blwr GB R X X X X X X X XMOTOR SHAFT VIBRATION (X-Y RADIAL) ALARM / TRIP 2 N.NN 3 / 5 MILS-PP 0.08 / 0.13 mm-pp MOTOR SHAFT DE / ODE VIBRATION X / Y - ALARM / TRIP Mtr ODE / DE RMOTOR BEARING VIBRATION ALARM / TRIP 2 N.NN 0.25/0.40 IPS-PK 6.4 / 10.2 mm/s-pk MOTOR BEARING DE / ODE VIBRATION - ALARM / TRIP Mtr ODE / DE RSHAFT KEYPHASOR (NOTE 12) - - - - -SEE PAGE 1 FOR NOTESBLOWER ANTI-FRICTION BEARING TEMPERATURE ALARM / TRIP 0 N.2/28/2008NUM. DEC. PLACESNUM. DEC. PLACES98% FLA102% FLA105% FLANUM. DEC. PLACESITEM C45 SEC248 / 266 F 120 / 130CN.N.N. 000RISING / FALLINGRISING / FALLING90 / 95C99 / 107C 210 / 225 F90 / 95CCOMPRESSOR SIZE (KA**) GEARBOX SERIES RISING / FALLINGRRRR XXXALARM / TRIPALARM / TRIPALARM / TRIP194 / 203 F194 / 203 FXXXXXXX XZ:\Submittal\Master\Item_C_OperationDesc\Source Docs\Instrument_Setpoints.Feb 2008.xls Printed: 12/5/2008 1635 W. Walnut Street Springfield, Missouri65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail:turblex@turblex.com Web Site:www.turblex.com ITEM E HI-TEMP COATING SYSTEM FORDISCHARGE TEMPERATURES UP TO 260C/500F BASE/OIL RESERVOIR Exterior Surface Preparation: SSPC-SP6 COMMERCIAL BLAST CLEAN Primer: One (1) Coat Sherwin Williams KEM 400 Metal Primer, B50-Z Series, 2.0-5.0 mils DFT Oil Reservoir Interior Surface Preparation: SSPC-SP10 NEAR WHITE METAL BLAST CLEANING NOTE: Reservoir coating application required within 10 hours of media blasting Oil Reservoir Coating:Two (2) Coats Devoe Coating Devchem 257Chemical Resistant Tank Lining, to achieve 10.0 to 15 mils (254-381 m) DFT. Color Intermediate White. Coating Application Instructions NOTE:Strict adherence to the manufacturers specification data sheets for minimum and maximum self recoat time (based on ambient conditions) as well as the directions for use is required. 1.Spray one (1) Coat of Devoe Devchem 257 to achieve 5.0-6.0 mils (127-152 m) DFT.Use a brush as necessary to ensure complete coverage of all hard to reach areas. 2.After minimum recoat time has elapsed but not exceeding the maximum (reference product data sheet), stripe coat all weld joints, gussets, corners and any other hard to spray areas within the reservoir. 4.Immediately after stripe coating, spray one (1) coat of Devoe Devchem 257 to achieve 5.0-6.0 mils (127-152 m) DFT. NOTE: Surface preparation and coating application by Detroit Tool. 2 COMPRESSOR/GEARBOX ASSEMBLY (AIR-END) Surface Preparation: SSPC-SP2 HAND TOOL CLEANING 1.Solvent Clean; using water and a water based cleansing agent cleaner, (Hydrocarbon Solvents Unacceptable) 2.Rinse Clean; rinse clean using water and a clean sponge, or clean cotton towel with a blotting technique, leaving no lent behind. Note: Do not force dry with pressurized shop air 3.Hand Scuff OEM Base Coat Surface; Using Red Scotch Bright pad to break the gloss of the OEM base primer. 4.Rinse Clean; rinse clean using water and a clean sponge, or clean cotton towel with a blotting technique, leaving no lent behind. Primer: One (1) Coat Sherwin Williams Hi-Temp Coatings No. 850 Primer, 1.0-1.3 mils DFT Top Coat: One (1) Coat Sherwin Williams Hi-Temp No. 850 Series, Black, 1.0-1.3 mils DFT COMPRESSOR SKID ASSEMBLY Surface Preparation: SSPC-SP1 SOLVENT CLEAN; using water and a water based cleansing agent cleaner, (Hydrocarbon Solvents Unacceptable) Primer: One (1) Coat Sherwin Williams Hi-Temp Coatings No. 850 Primer, 1.0-1.3 mils DFT Top Coat: One (1) Coat Sherwin Williams Hi-Temp No. 850 Series, Black, 1.0-1.3 mils DFT DISCHARGE CONE / BLOW-OFF SILENCER/ MISCELLANEOUS Surface Preparation: SSPC-SP6 COMERCIAL BLAST CLEAN Primer: One (1) Coat Sherwin Williams Hi-Temp Coatings No. 850 Primer, 1.0-1.3 mils DFT Top Coat:

One (1) Coat Sherwin Williams Hi-Temp No. 850 Series, Black, 1.0-1.3 mils DFT 3 COUPLING GUARD Surface Preparation: SSPC-SP1 SOLVENT CLEAN; using water and a water based cleansing agent cleaner, (Hydrocarbon Solvents Unacceptable) Primer: One (1) coat Sherwin Williams KEM 400 Metal Primer, B50-Z Series, 2.0-5.0 mils DFT Top Coat: One (1) coats Sherwin Williams KEM 400 Enamel, F75-400 Series, Safety Yellow, 1-1.5 mils DFT ELECTRICAL ENCLOSURES AND TERMINAL BOXES IF COATED FACTORY FINISH BY MANUFACTURER ANSI 61 Gray Polyester Powder Coating L:\Project_Engineering\Jobs\4607T\Engineering\Mechanical_Eng\O&M\Electronic_O&M\5044T Item E designed by Barry.doc.aj 1635 W. Walnut Street Springfield, Missouri65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail:turblex@turblex.com Web Site:www.turblex.com C:\Documents and Settings\beaty00b\Desktop\Blower_Performance_Test.doc ITEM F COMPRESSOR PERFORMANCE TEST NOTE:The following is the STE compressor test procedure.The official performance test report will be submitted in the final Operation and Maintenance Manual. Document Name: 4607T-Item FRev B 930930050US Revision:6 Page:1 of (9) TESTING OF TURBOCOMPRESSORS OPTION:ASME PTC-10 PROCEDURE Prepared by:WeDate:93.04.15 Latest revision:WeDate:98.03.31 1.Purpose 2.National and International Standards 3.Measuring Equipment, Instrumentation, and Calibration 4.Test Procedures/Standard Shop Test (SST)/Witnessed Performance Test 5.Documentation 6.Additional Testing 1.Purpose All testing is performed in order to measure operating data for evaluation of conformity with specified data. Beforedelivery,eachHV-TURBOcompressoristestedinaccordancewithHV-TURBO's StandardShopTest(SST)Specification.Thetestprocedureshavebeendevelopedduring decades of testing thousands of turbo-machines. The test must fulfil the following purposes: a)providesufficienttestdataovertheentirespecifiedoperationalrangeforthequality approval procedure before delivery b)provide documentation of the performance data and the performance range in terms of a graphic presentation to the customer c)provide conditioned data/software for the automated power saving program of SV-type compressors d)provide specific and statistic data as feedback for the compressor design program e)ensure accurate, safe, and fast registration of all relevant test data in the shortest possi-ble testing time and at the lowest possible cost. 2.National and International Standards/Norms It is mandatory that especially all logging and evaluation of performance data conform with the relevant national and international standards. Item F 930930050US Revision:6 Page:2 of (9) TESTING OF TURBOCOMPRESSORS OPTION:ASME PTC-10 PROCEDURE HV-TURBOcompressortestingprocedures,aswellasthetestingequipment,instrumenta-tion,andcalibrationareinconformitywiththenationalandinternationalnormsoftesting turbo-compressors, as follows: ISO 5389:International standard: Turbocompressors - Performance Test Code. ISO 5167:International standard: Measurement of Fluid Flow. ASME PTC-19.5:USA-standardforflowmeasurement,basedonthesametypeof equipmentandthesamephysicallawsasISO5167,butmore complicatedtohandleduetononmetricunitesandtraditional methods.ComparedtoISO5167,thePTC-19.5computationsof flow,measuredbythesame concentric orificeplate,willresultin flowfigureswhichareequalorupto%higherthanISO5167 computations.FortheevaluationoftestresultsHV-TURBOhas implemented the ISO 5167, which is assumed to be the most mod-ern/updatedstandard,andwhichdoesnotconflictwiththePTC-19.5. ISO 10816-1:Mechanical Vibration of Machines. ISO 3744:DeterminationofSoundPowerLevelsofNoiseSources.Iffree-field conditions can not be established, ISO 3746 will apply. ASME PTC-10:Compressors and Exhausters, Power Test Codes (please see also 4.3). 3.Measuring Equipment, Instrumentation, and Calibration 3.1Flow Measurements Allflowmeasurementsduringshoptestsarecarriedoutbymeansofstraight,cylindrical measuring pipesonwhichtheentryofeachpipeisequippedwithastraightener.Thepipe length for inflow and outflow, the orifice plate design, and the pressure tappings are in accor-dance with the specified standards. At the exhaust of each pipe, an electrically activated throt-tle valve is installed in order to adjust the discharge pressure level. The pipe inlet temperature is measured by 4 calibrated temperature probes. The measuring pipe is carefully insulated to avoidheatlosses=temperatureerrors.Thepipesystempressureismeasuredbydifferent pressureprobes.Fordifferentflowrates,measuringpipesofdifferentdimensionsarein-stalled on the test bed. The orifice plates are inspected, calibrated, sealed, and certified every year by the independ-ent international inspection company SGS (Socit Gnrale de Surveillance). The flow is computed from readings of pressure, temperature, and humidity. The method of computation is described in the above mentioned standards ISO 5167/PTC-19.5. Item F 930930050US Revision:6 Page:3 of (9) TESTING OF TURBOCOMPRESSORS OPTION:ASME PTC-10 PROCEDURE 3.2Measuring Shaft Power The shaft power can be measured in various ways, depending on the test rig used. 3.2.1Direct Method by Torquemeter The torquemeter is an electronic torque measuring coupling installed between the drive motor and the compressor. Different sizes of torquemeter couplings are available. The shaft power is computed from the measurement of torque and RPM. Alltorquemetercouplingsarecalibratedonstandardizedcalibrationrigswithcertified plummets. Calibration of the torquemeter couplings is inspected and certified once a year by the SGS. 3.2.2Indirect Method of Measurement A.This method may be applied with compressors packaged with the job motor: When the compressor is driven by an electric motor, the power input at the terminals can be measured. The input power is multiplied by the motor efficiency, which equals the shaft power. In order to obtain true data, two requirements must be fulfilled: a)The motor power input must be measured with calibrated instruments. b)The motor efficiency must be verified by a motor test, involving measuring of the power input and of the shaft power with e.g. a calibrated torquemeter. Alternatively, the motor efficiency can be determined by other methods equivalent to those required when using the direct method. Theaccuracyofthetestdatashouldalwaysbedocumentedbyvalidcalibrationcer-tificates. When measuring the motor power input HV-TURBO have six different power supply systems(380Vto10kV)attheirdisposal,withcalibratedandsealedkWh-counters.Valid calibration documents are provided by an authorized calibration office for kWh-counters. In addition, each power supply line is monitored by independent meters for kW, Amps and Volts. B.The heat balance method of shaft power measuring is independent of any motor input measuring or calibration of efficiency. When using the heat balance method, the shaft power is computed from the measurements of the energy input into the gas, the mass flow,thegearlosses,bearinglossesetc.,inaccordancewithISO5389andASME PTC-10. Item F 930930050US Revision:6 Page:4 of (9) TESTING OF TURBOCOMPRESSORS OPTION:ASME PTC-10 PROCEDURE 3.3Temperature Measurement Standard temperature measurements are carried out by 4 temperature probes at the compres-sor intake and 4 similar probes at the compressor discharge. Theprobes are thermocouplesofanindustrialdesign,wired to ahighprecisiondigitaldis-play. All temperature probes and wires are marked for identification, sealed by SGS, and cali-brated in a laboratory calibration device. The calibration is performed with reference to cer-tifiedthermometers.Thecalibrationoftemperatureprobes,incl.wiringanddisplay,is checked regularly and inspected and certified once a year by SGS. 3.4Pressure Measurement Ingeneralpressuremeasurementsarecarriedoutbymeansofhighprecisionelectronic transmitters with digital reading. These instruments are always calibrated. U-tubes with water or mercury filling are installed for the verification of these instruments. 3.5Transmitters for the Automated Test Data Logging The test facility is equipped with fast-logging multichannel data sampling units connected to thetestbedcomputersystem.Alltestdataareconvertedintoelectronicdataforautomatic datalogging.Alltransmittersinvolvedarecontinuouslycheckedandmaintainedinacor-rectly calibrated state. This system is supporting the SST, please see 4.2. 3.6ISO - 9001 Procedures HV-TURBO is operating a certified quality assurance system for a.o. continuous calibration inconformitywiththerequirementsoftheinternationalISO9001standard.Alsothistest procedure description including all stated commitments is a registered document within this quality system. 3.7Certification Ingeneral,thea.m.certificationofinstrumentcalibrationiscarriedoutbySGS.Formore than a decade calibration of our test bed instruments have proven that calibration data for the sameinstrumentsdonot changebymorethanwhatisexpectedwithinthe specified instru-ment accuracy. SGS (Socit Gnrale de Surveillance) is an independent international inspection company with head office in Geneva, Switzerland, and with more than 100 assigned SGS-offices, pla-ced all over the world. SGS certificates issued for a HV-TURBO calibration or compressor test can be verified by any office of the SGS organisation. Item F 930930050US Revision:6 Page:5 of (9) TESTING OF TURBOCOMPRESSORS OPTION:ASME PTC-10 PROCEDURE Ifother calibrationprocedures arerequired, this must bespecifiedin the contractoragreed upon within a suitable space of time prior to the scheduled testing. 4.Test Procedures 4.1Planning and